Innovative packaging systems cut packaging waste in truck manufacture

MAN Nutzfahrzeuge AG is using Conteyor Multibag material handling systems to package components for its Trucknology Generation A (TG-A) trucks, voted 2001 Truck of the Year.

At its base in Munich, MAN Nutzfahrzeuge AG uses approximately 1800 containers based on three different standard systems from Conteyor Multibag NV (Belgium) for more than 10 interior and exterior truck components. MAN also uses Conteyor systems in its plants at Salzgitter (Germany), Vienna (Austria) and Steyr (Austria).

Conteyor Multibag systems are an ergonomic, efficient and environment-friendly way to transport large, delicate parts. Conteyor developed the systems in close co-operation with MAN, in a pilot project at the automotive manufacturer’s Munich plant. In contrast to conventional rigid packaging systems, Conteyor Multibag systems use suspended textile-based bags to carry the parts. The bags offer excellent protection without the need for further packaging, yet leave the components easily accessible.

“Today’s trucks offer a high-quality environment that compares well with the interior of a passenger car,” says Peter Lipps of MAN’s Inventory Logistics Department. “Many of our cabin parts have light-coloured textile surfaces that must be protected against stains and dust, so we need anti-static packaging materials. The packaging must also prevent painted body panels from getting scratched. The fewer the unpacking steps, the better for the product.”

For the large interior rear and sidewall panels of the driver cabin and the roof inner liner, the ideal solution is the Conteyor Multibag System. Guided on tubular crossbars, the Multibag System always offers the next part ready for use.

All the fitter has to do is remove the part from the bag, with no further unpacking. This saves time and prevents accidents caused by sharp-edged packaging materials. It also eliminates the waste and associated disposal costs that characterise other packaging systems.

The bags are exchangeable, can be easily cleaned, and ensure excellent product protection particularly for large and sensitive parts. At the same time they provide high packaging densities.

For the sliding sunroof and the intermediate storage box of the TG-A, MAN selected the Conteyor Shelves System. This consists of a wheeled container with semi-rigid tensed compartments or pockets. Spacing possibilities are virtually unlimited, and the Conteyor Shelves System is especially suitable for sequenced parts.

The Conteyor Partition System proved to be the ideal packaging choice for the fenders, door extensions, side spoilers and side storage box covers of the MAN truck. This system fits in standardised handling containers, can be exchanged and is also available in a folding configuration. A special variant with moveable partitions serves for various smaller plastic components.

“Everything is neatly stowed away but ready at hand, and there is no more packaging waste to collect and take away,” says Wilhelm Fritsch, responsible for Container Management at MAN. “The systems also meet with high acceptance among our suppliers. And in the case of small design changes, we have repeatedly saved several hundreds of deutschmarks in conversion costs that would have resulted from packaging systems in which the parts are fixed in rails.”